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CS-06: Pump & Valve Components — Sand Casting to Lost Wax — Amsol Industries
06
Target
Price Achieved
↑
Surface Finish
Low Vol
Economical Solution
Case Studies›Pumps & Fluid Systems›CS-06
Pumps & Fluid SystemsPumps & Fluid Systems

Pump & Valve Components — Sand to Lost Wax Conversion

A customer in the pump and valve industry submitted drawings for steel sand castings. The parts were light, the volumes were low — and every foundry they had approached said the same thing: not feasible at your volumes. Amsol looked at the drawings and gave them a different answer.

Key Outcome
Amsol reviewed the part weight, annual volume, and tolerance requirements — and recommended process conversion to investment (lost wax) casting. Not only was it feasible — the surface finish was better and the unit economics worked at low volume.
The Situation

Why Sand Casting Was the Wrong Process for These Parts

Light steel components at low volume are exactly where conventional sand casting becomes economically marginal. Sand foundries need batch volume to justify setup cost. The customer's components were too light and too few — hence the rejections. Investment casting does not have this constraint.

Investment casting is equally economical from 50 pieces to 50,000. The process cost per part does not rise dramatically at low volume because there are no batch minimums and no high-cost moulding setup. This is the process that was designed for exactly this scenario.

The Problem
What the OEM was facing.
✕Conventional steel sand foundries required minimum batch volumes the customer could not justify
✕Light components in sand casting = higher scrap rate per kg of usable metal
✕Surface finish from sand casting (Ra 12–25 µm) required significant post-cast machining
✕Multiple foundries rejected the enquiry as uneconomical at the customer's volumes
✕Customer's target price was not achievable through sand casting at these quantities
Amsol's Approach
The engineering-led solution.
✓Investment casting is economical from 50 pieces — no batch minimum constraint
✓Near-net-shape investment casting: Ra 1.6–3.2 µm as-cast — much less machining needed
✓DFM review reduced machining allowances — further lowering total production cost
✓Material: CF8M stainless or carbon steel — both castable in investment process
✓Target price achieved — full cost breakdown presented before any tooling commitment
What Amsol Did

Process Conversion: Why Investment Casting Won

The comparison below shows why investment casting was the correct answer for this customer's specific combination of part weight, volume, and tolerance requirement.

Sand Casting (Original)
Minimum batchHigh — not viable
Surface finishRa 12–25 µm
Machining neededSignificant
Unit economicsNot viable at this volume
Investment Casting (Amsol Solution)
Minimum batch50 pieces — no constraint
Surface finishRa 1.6–3.2 µm ✓
Machining neededMinimal
Unit economicsTarget price achieved ✓
"
The right process is not the one the customer asks for. It is the one that delivers the required performance at the lowest total cost for the given volume, geometry, and material. Amsol identifies that answer — and then builds it.
Amsol Engineering Team
The Results

What the Programme Delivered

Every result below is documented and traceable to this supply programme.

Target
Price Achieved
Customer's target price met — within the volume and geometry constraints that sand casting could not address
↑
Surface Finish
Ra 1.6–3.2 µm as-cast versus Ra 12–25 µm in sand casting — far less machining required
Low Vol
Works Economically
Investment casting is viable from 50 pieces — the constraint that eliminated every sand foundry was removed
Active
Supply Established
Reliable supply chain for low-volume precision pump and valve components — ongoing programme
Pump or Valve Components
Light Components at Low Volume?
If your pump or valve components are being rejected by sand foundries as uneconomical, investment casting may be the right answer. Amsol will assess your drawing, volume, and tolerance requirements — and tell you which process works.
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